operating instructions high-z standard-series - cnc-step · 3/14/2015 · cnc-step e.k....

Status: 14.03.2015

Operating Instructions

High-Z Standard-Series

S-400 ▪ S-720 ▪ S-1000

www.cnc-router.com

http://www.cnc-router.com/



CNC-STEP e.K. ▪ Siemensstrasse 13-15 ▪ 47608 Geldern ▪ Germany

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Short description

The machine includes the complete mechanics for three-dimensional movement. The linear

carriage-movement takes place via threaded spindles, powered by step motors. Two drives are used

on the x-axis. The activation of the step motors, in order to operate every single axis, is done by

using further interfaces. This operating description will show you how to install, operate and service

a CNC- portal system.




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Contents

1 GENERAL ..................................................................................................................... 7

1.1 Symbol description ................................................................................................................... 7

1.2 Limitation of Liability .............................................................................................................. 8

1.3 Copyright .................................................................................................................................. 8

2 SAFETY ........................................................................................................................ 9

2.1 Intended use .............................................................................................................................. 9

2.2 Fundamental dangers ............................................................................................................ 10

2.2.1 Hazards from electrical power ........................................................................................... 10

2.2.2 Dangers by mechanics ....................................................................................................... 11

2.2.3 Dangers by high or very low temperatures ........................................................................ 13

2.2.4 Risk of fire ......................................................................................................................... 13

2.2.5 Radiation hazards .............................................................................................................. 14

2.2.6 Hazards of chemicals ......................................................................................................... 14

2.2.7 General work-related dangers ............................................................................................ 16

2.3 Responsibility of the operator ............................................................................................... 17

2.4 Staff requirements .................................................................................................................. 18

2.4.1 Qualification ...................................................................................................................... 18

2.4.2 Instruction .......................................................................................................................... 19

2.5 Personal protective equipment .............................................................................................. 19

2.6 Safety installations .................................................................................................................. 20

2.6.1 Description of the installed safety installations ................................................................. 21

2.6.2 Safety installations, which have to be updated by the owning operator ............................ 22

2.7 Behaviour in case of fire or accidents ................................................................................... 22

2.8 Environmental protection...................................................................................................... 23

2.9 Signage ..................................................................................................................................... 23

2.9.1 Mandatory signs ................................................................................................................ 24

2.9.2 Prohibition signs ................................................................................................................ 24

2.9.3 Warnings ............................................................................................................................ 25

2.9.4 Fire protection signs .......................................................................................................... 26

2.9.5 Exit signs ........................................................................................................................... 27

3 TECHNICAL SPECIFICATIONS ................................................................................ 28

3.1 General information ............................................................................................................... 28

3.2 Power values ........................................................................................................................... 30




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3.3 Operating conditions .............................................................................................................. 30

3.4 Working materials .................................................................................................................. 30

3.5 Emissions ................................................................................................................................. 30

3.6 Type plate ................................................................................................................................ 31

4 STRUCTURE AND FUNCTIONS ................................................................................ 32

4.1 Overview ................................................................................................................................. 32

4.2 Brief description of the application range ............................................................................ 33

4.3 Module Description ................................................................................................................ 34

4.3.1 Z-axis with carriage ........................................................................................................... 34

4.3.2 Y-axis with carriage ........................................................................................................... 35

4.3.3 X-axis with carriage ........................................................................................................... 36

4.3.4 Tool holder ........................................................................................................................ 37

4.4 Controls ................................................................................................................................... 37

4.5 Connections .......................................................................... Fehler! Textmarke nicht definiert.

4.5.1 Control signals (ST)........................................................................................................... 39

Motor connector (X1,X2,Y,Z) ........................................................................................................ 39

4.5.2 MiniXLR pin socket (Pin15) ............................................................................................. 40

4.6 Work and danger areas ......................................................................................................... 41

4.6.1 Working area ..................................................................................................................... 41

4.6.2 Danger zone ....................................................................................................................... 41

5 TRANSPORT, PACKAGING AND STORAGE ........................................................... 42

5.1 Safety instructions for transport ........................................................................................... 42

5.2 Transport inspections ............................................................................................................ 43

5.3 Packaging ................................................................................................................................ 44

5.4 Symbols on packaging ............................................................................................................ 45

5.5 Transport ................................................................................................................................ 45

5.6 Storage ..................................................................................................................................... 47

6 INSTALLATION AND COMMISSIONING ................................................................. 48

6.1 Safety instructions for the installation and commissioning ................................................ 48

6.2 Preparations ............................................................................................................................ 49

6.2.1 Install machine ................................................................................................................... 49

6.2.2 Install worktop ................................................................................................................... 50

6.3 Installation .............................................................................................................................. 50




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6.3.1 Connecting the computer ................................................................................................... 50

6.3.2 Connecting the stepper motor and control cable ............................................................... 51

6.3.3 Installing Accessories ........................................................................................................ 52

6.4 Initial start-up ......................................................................................................................... 53

7 OPERATION ............................................................................................................... 54

7.1 Safety guidelines for operation .............................................................................................. 54

7.2 Operations before usage ........................................................................................................ 54

7.3 Switching on ............................................................................................................................ 54

7.4 Activities during operation .................................................................................................... 55

7.4.1 Operating machine ............................................................................................................. 55

7.4.2 Change tool ........................................................................................................................ 58

7.5 Switching off ........................................................................................................................... 58

7.6 Activities after use .................................................................................................................. 59

7.7 Emergency Shutdown ............................................................................................................ 59

8 MAINTENANCE ......................................................................................................... 60

8.1 Safety Instructions for maintenance ..................................................................................... 60

8.2 Spare parts .............................................................................................................................. 61

8.3 Maintenance Schedule ........................................................................................................... 62

8.4 Maintenance ............................................................................................................................ 63

8.4.1 Cleansing of the machine .................................................................................................. 63

8.4.2 Lubricate machine ............................................................................................................. 64

8.5 Measures after maintenance ................................................................................................. 68

9 FAILURES .................................................................................................................. 69

9.1 Cautions for Troubleshooting ............................................................................................... 69

9.2 Diagnosis Chart ...................................................................................................................... 71

9.3 Problem resolution ................................................................................................................. 73

9.3.1 Cancel the emergency stop ................................................................................................ 73

9.3.2 Check axes for perpendicularity ........................................................................................ 73

9.3.3 Description of process for aligning the machine with respect to perpendicularity ........... 74

9.4 Commissioning after fault has been rectified ...................................................................... 74

10 DISMANTLING AND DISPOSAL ............................................................................ 75

10.1 Safety regulations for the disassembling and disposal .................................................... 75




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10.2 Disassembling ...................................................................................................................... 75

10.3 Disposal ................................................................................................................................ 76

11 APPENDIX ............................................................................................................... 77

11.1 Accessories ........................................................................................................................... 77

12 CUSTOMER SERVICE ............................................................................................ 78




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1 General

This instruction provides guidelines which enable a safe and efficient handling of the machine. The

manual is an integral part of the machine and must be kept in the immediate vicinity of the machine

and accessible at any time for the personnel.

Before starting all tasks, personnel must carefully read and understand these instructions.

Adherence to all the specified safety instructions and instructions for actions in this operating

manual is a fundamental requirement for working safely.

Furthermore, the local accident prevention regulations and general safety conditions for the

application of the machine are also applicable.

Illustrations in this manual are intended to facilitate basic understanding, and may differ from the

actual design.

Further guidelines regarding built-in components are found in the appendix of this description.

1 .1 Symbol descript ion

Safety instructions are designated by symbols. In addition, there is always a signal word

heading the information indicating the severity of the danger or hazard that may be

encountered.

HINT:

Indicates a potentially hazardous situation which, if not avoided, could result in

property damage or environmental contamination.

WARNING:

This signal word and symbol indicates a risk which can lead to severe injury or even

death, if not avoided.

ATTENTION:

This signal word and symbol indicates a risk which can lead to small injuries, if not

avoided.

Danger:

This signal word and symbol indicates a risk which can lead to severe injury or even

death, if not avoided.

Prohibition for people with pacemakers

This sign stands for activities involving risks for people with pacemakers. These areas

are prohibited for people with pacemakers!!




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1 .2 Limitat ion of Liabi l i ty

All data and notes in these instructions were prepared with consideration to the statutory standards

and regulations, the present state of technology, as well as our many years of knowledge and

experience.

Under the following circumstances the manufacturer will not assume any liability:

Non-compliance with these instructions

Used other than for the intended purpose

Unauthorized or unapproved personnel

Unauthorised rebuilds or modifications

Unauthorized technical changes

The use of unauthorized replacement parts or non-original accessories

The actual scope of delivery can, by special designs, deviate from the explanations and

presentations given here, because of the utilization of additional order options, or because of the

most recent technical changes.

The responsibilities agreed in the delivery contract, the General Terms and Conditions as well as the

delivery conditions of the manufacturer and the statutory regulations valued at the time of

conclusion of the contract are effective.

1 .3 Copyright

The contents of this instruction are copyrighted. It is to be used for the purpose of operating the

machine, only. Any other use without a written permission is forbidden.

Warning of hazardous electrical voltage

This sign stands for activities on all components carrying live voltage.

Danger due to hot surface

This sign stands for activities involving contact with hot objects.




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2 Safety

This section gives an overview of all important safety aspects for optimum protection of the

personnel, as well as for the safe and fault-free operation. Other task-based guide-lines are included

in the sections regarding the individual phases of life.

2 .1 Intended use

The CNC-Portal system is exclusively used for holding provided tools that serve to process various

materials and surfaces.

The machine is meant to be built into a complete system and does not have its own control unit.

Intended use also includes compliance with instructions specified by the manufacturer concerning

operation, servicing and maintenance.

Every application in excess of the intended use and/or other use, can lead to hazardous situations

and is considered misuse.

WARNING:

Danger due to misuse!

Improper use of the CNC-portal machine can cause dangerous situations.

Operation outside the values specified in the section „Technical data“.

Bypassing the safety devices.

Remodelling, refitting or changing of the device or parts of it, with the

intention to alter functionality or usability.

If machining process involves flammable cooling lubricants.

Processing light alloys such as aluminium, magnesium and titanium alloys

without extraction attachments and corresponding safety measures.

Operating the machine, although it is not in perfect condition from a technical

point of view.

Operating the machine in potentially explosive environment.

The manufacturer shall not be held liable for any and all damage due to misuse of this equipment.




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2 .2 Fundamental dangers

In following section, all residual risks are named that can still result from the machine, even when

the appliance is used as intended.

In order to minimize personal injuries and property damage and avoid dangerous situations, all here

mentioned safety-guidelines and those mentioned in further sections must be followed.

2 .2 .1 Hazards from electrical power

Electric current

DANGER:

Life Hazard through electrical shock!!

Touching conductive parts causes a direct danger to due to electrical shock.

Damage to the insulation or individual components can mean danger to life.

Any work required at the electrical system may only be carried out by a

qualified electrician in compliance with electro-technical regulations.

In case of damage to the insulation, switch off the power supply

immediately and have repairs carried out.

Before starting to work on active parts of electrical systems and equipment,

establish a voltage-free state throughout the duration of the work, this must

take place according to the 5 following safety regulations:

Activation.

Secure it from being switched on again.

Determine voltage free status.

Earth and short circuit.

Provide protection by covers or barriers for any neighbouring live parts.

Never attempt to bypass or de-activate fuses or cut-outs. When replacing fuses

or circuit breakers make sure to adhere to the correct ampere rating. Keep

moisture away from live parts.




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Stored charge

Danger:

Risk of death due to stored voltage!

Electronic charges could be stored in electric components that still exist after

switching off and disconnecting from power-supply. Contact with these components

can lead to severe injury or even death.

Before starting work disconnect mentioned components from power-supply.

Wait 10 minutes, in order to assure that the internal capacitors discharge

completely.

2 .2 .2 Dangers by mechanics

Rotating tools

WARNING:

Risk of injury from rotating tools!

Clamped tools such as milling spindles can lead to severe personal injury or

material damage.

Before the start of any work, ensure that all covers and protective devices are

correctly installed and function correctly.

Never touch moving tool during operating process!

Before exchanging tools, always pull power plug of the milling motor or turn

off the machine and secure against restarting.

Axis motion

WARNING:

Risk of injury by axis motion!

Collision by people with components of the machine (Y-bridge, Units, turntable with

work piece, tools) can cause severe injuries.

Body parts are kept away from moving components and axis limit switches.

Do not reach into gaps between trapezoidal screws and adjacent

components.

Do not reach into gaps between unit and Y-bridge.

Only work on the machine when it is idle.

Only work with personal safety equipment.




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Falling materials

WARNING:

Injuries by falling materials!

During operation chips, tools (or parts of it) could be thrown out uncontrollably or

cause severe injuries to skin and eyes.

Wear face shield or fully closed and tight-fitting goggles, protective

clothing, protective gloves and safety shoes.

If particles enter your eyes, immediately get medical attention!

Unexpected start-up of the machine

WARNING:

Risk of injury caused by unexpected start-up of the machine

The machine and the used tools can start-up unexpectedly, change their direction or

stop. Limps can get trapped.

It must be ensured that, no body parts get in the danger zone of the machine.

Protect working area against unintentional access.

Tools

ATTENTION:

Risk of injuries by negligent handling of tools!

By handling tools negligent, lacerations and crushing injuries can be caused.

Tools must be handled with care and used in accordance with the

regulations.

Take weight into account when transporting tools.

Wear safety shoes and protective gloves.

Sharp edges and corners

ATTENTION:

Risk of injuries by sharp edges and corners!

Sharp edges and corners can cause abrasions and cuts on your skin.

Working near sharp edges and corners should be done with great caution.

If in doubt wear protective gloves.




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2 .2 .3 Dangers by high or very low temperatures

Hot surfaces

ATTENTIONS:

Risks by hot surfaces!

Tools, work pieces and chips can heat up during operation. Skin contact with hot

surfaces causes serious burns of the skin.

As a matter of principle, for all tasks with tools, work pieces and chips,

protective clothing and gloves must be worn.

Before all tasks, make sure that all surfaces have cooled down to the

ambient temperature.

2 .2 .4 Risk of f ire

Highly flammable materials

ATTENTION:

Risk of fire by highly flammable materials!

Organic dust produced by coal or wood or inorganic dust from magnesium,

aluminium, zinc or titanium can catch fire and cause severe injuries and death.

Do not smoke within the danger zone and the immediate vicinity. Refrain

from contact with open flames or sources of ignition.

Keep a fire extinguisher at hand in the immediate vicinity of the work area.

Do not process light alloys such as magnesium, aluminium, zinc and

titanium without an extraction system and relevant security measures.

Suspend any work activities in case of fire. Leave the danger zone until the

all clear signal is given




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2 .2 .5 Radiat ion hazards

Magnetic fields

DANGER:

Danger to life by magnetic fields!

Magnetic fields of step motors can cause severe injuries or death, as well as serious

damage to materials.

Persons with pacemakers must keep away from the machine! It can

effectively provoke a dysfunction of the pacemaker.

Persons with metallic implants must not be allowed in the area of the

machine. Implants can heat themselves up or be drawn-in.

Take off all metal objects (Jewellery, watches, pens etc.) before starting

maintenance operation.

No electronica equipment is to be taken into the magnetic source area. These

could get damaged.

No storage media, credit cards etc. are to be taken into the magnetic source

area. Containing data may be deleted.

2 .2 .6 Hazards o f chemicals

Cooling emulsion

WARNING:

Danger of serious damage to health by polluted cooling emulsion!

Polluted cooling emulsion can cause inflammations when coming in contact with

skin.

Cooling emulsion must be checked at regular intervals.

When handling with polluted cooling emulsion protective clothing and

chemical-resistant safety-gloves must be worn.

Avoid direct skin contact. Cleanse skin, especially before breaks and when

finishing work.

Eat and drink in relevant break room only!




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ATTENTION:

Health risks due to contact with cooling emulsion!

Contact with cooling emulsion may lead to health risks.

Avoid contact with your skin.

Remove cooling emulsion from the skin immediately.

Do not inhale the vapours.

Oil and fat

ATTENTION:

Risk of health due contacting with oil and fat!

Contact with oil and fat may lead to health risks.

Avoid skin contact.

Remove oil and fat immediately from skin.

Do not inhale vapours.




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2 .2 .7 General work-related dangers

Noise

ATTENTION:

Risk of injury by noise!

The noise levels occurring in the operating area may cause severe hearing damage.

Always wear hearing protection when working.

Only stay in the danger area when required.

Dirt and objects lying around

Attention:

Risk of tripping by dirt and objects lying around!

Soiling and objects left lying around are sources of slipping and stumbling and can

cause considerable injuries.

Always keep the work area clean.

Remove any objects which are no longer required from the working area,

especially those near ground.

Designate tripping positions with yellow-black marker band.




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2 .3 Responsibi l i ty of the operator

Operator

Operator is the person who operates the machine for commercial or economic purposes, or leaves

the use / application to a third party and bears responsibility during the operation of the product for

the protection of the user, the staff and third party.

Operator obligations

The machine is used in the commercial sector. The operator of the machine is therefore subject to

the legal obligations concerning occupational safety. Apart from the safety instructions given in this

manual, it is necessary to meet all safety, accident prevention and environmental protection

requirements applicable to the equipment's field of use and operating site.

The following principles apply in particular:

The operating company must inform itself about the effective industrial regulations and

determine additional hazards in a risk assessment that result through the special working

conditions at the place of operating the machine. He must implement this in the form of

operating instructions for the operation of the machine.

During the complete usage time of the machine, the owner must check whether the

operating instructions created by him correspond with the current status of the regulations

and must adapt them if necessary.

The owner must clearly regulate and specify the responsibilities for installation, operation,

maintenance and cleaning

The operator of the machine must ensure that all persons having access to it, have read and

understood these instructions. In addition he must at regular intervals train the employees in

how to deal with the machine and inform them about potential hazards.

The operating company must provide the required safety equipment for the personnel and

order to wear protective equipment.

Moreover, the equipment operator is responsible for ensuring that the equipment is in proper

technical condition at all times.

Thus, following applies:

The operating company must make sure that any and all maintenance intervals described in

this instruction are carried out.

The owner must arrange for all safety equipment to be checked regularly for functionality

and completeness.




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2 .4 Staff requirements

2 .4 .1 Quali f icat ion

The different Tasks contained in this instruction require different qualifications auf persons that are

intrusted with these tasks.

WARNING:

Risks caused by insufficient qualifications of persons!

Insufficient qualified persons cannot assess the extent to which they represent a risk

handling with the machine and therefor run the risk of injuries or death for

themselves and others.

Work on or in the unit must be done only by duly qualified staff and in full

compliance with the appropriate instructions and pertinent regulations...

Keep insufficiently qualified persons away from the work area.

Only persons of whom it may be expected that they perform their work reliably are permitted as

personnel. Persons whose responsiveness is affected, e.g. by drugs, alcohol or medicines are not

authorized.

In this instruction all required qualifications, for the different people, with different tasks are

named:

Operator

The operator was instructed by the operating company in a briefing about the tasks assigned to them

and instructed about possible hazards because of improper conduct. Tasks, die which are carried out

beyond the normal operation, only are allowed to be carried out by an operator if this is mentioned

in this instruction and the operating company has assigned the operator expressly.

Electrician

An electrician whose technical training, skills and experience together with their knowledge of

pertinent regulations and documentation means that they are capable of assessing the work to be

carried out and detect and prevent any possible dangers.

An electrician is trained especially for its working environment, and knows the relevant standards

and regulations.

Qualified personnel

Qualified personnel based on their professional training, know-how and experience as well as

knowledge of the applicable standards and regulations is able to perform assigned work activities

and to detect and to avoid possible dangers on their own.




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Manufacturer

Curtain maintenance work is only allowed to be carried out by authorized and skilled personnel.

Other personnel is not authorised to carry out these tasks. In order to carry out this maintenance

work, please call our customer service!

2 .4 .2 Instruct ion

The owner must train staff regularly. For record-keeping purposes, a log of training conducted must

be kept with following minimum contents:

Date of training

Name of trained person

Contents of training

Name of trainer

Signature of trained person and trainer

2 .5 Personal protect ive equipment

Personal protective equipment prevents from impairments with respect to the safety of personnel

during work.

Personnel have to wear personal protective equipment while working on the machine, which are

mentioned in different sections of this instruction.

Description of personal

protective equipment

Protective clothing

Protective clothing is close fitting, with low resistance to tearing, with narrow sleeves

and without protruding parts.

Chemical resistant safety gloves

Suitable chemical resistant safety gloves have to worn to protect your skin from

aggressive chemicals.




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2 .6 Safety instal lat ions

WARNING:

Malfunctioning safety installations may pose a fatal risk!!

Malfunctioning or deactivated safety installations may cause severe injuries and

even death!

Before starting to work, check all safety installations regarding their

functional efficiency and correct installation.

Never deactivate or bypass safety equipment.

Take care to ensure that safety installations are always accessible.

Hearing protection

Hearing protection prevents irreversible damage to hearing.

Industrial protection helmet

Industrial protection helmet prevents from injuries by falling or suspended objects.

Safety glasses

Safety glasses prevent injuries in eyes from parts flying around or squirts of fluids.

Protective gloves

Protective gloves protect the hands from rubbing, abrasions, cuts or more profound

injuries, as well as when touching hot surfaces.

Protective cover

Wear protective cove to protect long hair from being caught, wrapped up in, or drawn

into moving parts.

Employees are required to wear protective covers, if their hair is longer than the extent

of the shaft and its moving parts.

Safety boots

Safety shoes protect the wearer's feet against falling objects, from being crushed,

slippery surfaces and being run over by vehicles.




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2 .6 .1 Descript ion of the instal led safety instal lat ions

Emergency-stop-

button

Figure1: Emergency-stop-button

By pressing the emergency-stop-button (Figure 1) the machine is shut down by immediately

switching off the energy supply to the machine drives. After pressing the emergency-off-button, it

has to be turned to be able to turn the machine on again.

WARNING:

Danger to life when unintentional switching the machine back on!

Unintentional start-up of the machine can lead to severe injuries and death.

Before switching on the machine make sure, that the cause of the

emergency-stop is eliminated and all safety installations are correctly

installed and functional.

Only unlock the emergency-stop-button (Figure 2 u. 3) when there is no

risk.

Position of emergency-stop-button

Figure 2:Emergency-stop-button on

Y- bridge

Figure 3: Emergency-stop-button on step-motor controller




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2 .6 .2 Safety instal lat ions , which have to be updated by the

owning operator

Extraction

When processing light metal alloy such as magnesium, aluminium and titanium an extraction

system has to be installed.

HINT: Risks to human health and environment!

Wrong handling and no extraction system can cause production of particulate matter.

Particulate matter damages mostly the airways, because it gets inhaled. Following

health effects related to particulate matter concentrations are generally known:

Temporary impairments of the repertory

Higher medication requirements for asthma patients

Increased hospital admissions

Increased mortality caused by cardiovascular problems and respiratory

diseases

2 .7 Behaviour in case of f ire or accidents

Preventive measures

Always be prepared for accidents or fires!

Keep first aid facilities (first aid box, blankets etc.) and fire extinguishers accessible at all

times.

Familiarise personnel with accident reporting, first aid and rescue equipment.

Keep access routes clear for rescue vehicles.

Measures for fire and accidents

Cause emergency-stop by pressing emergency-stop-button immediately.

If there is no risk for own health, remove all persons from the danger zone.

Instigate first aid measures, if necessary.

Call the fire brigade and/or rescue service.

Fire: Fight fire with fire-extinguishers, if there is no risk for own health. Continue fire-

fighting until fire-brigade arrives.

Inform responsible persons at the place of action...

Clear access routes for emergency vehicles.

Instruct rescue vehicles.




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2 .8 Environmental protect ion

HINT: Risk for environment caused by carelessly handled hazardous

substances!

Handling with hazardous substances can be dangerous for the environment if

handled carelessly, especially when disposed wrong. This can cause severe

damages to the environment.

Please pay attention to the correct handling and disposal of below

mentioned hazardous substances.

If environmentally hazardous substances are accidentally released into

the environment, take suitable measures immediately. In case of doubt

inform the responsible local authority of the damage

Lubricants Lubricants, such as grease and oils, contain toxic substances. They must not

reach the environment. The disposal must be taken place by a specialised waste

management company.

Gear oil Gear oil contains many toxic substances. They must not reach the environment.

The disposal must be taken place by a specialised waste management company.

Cooling emulsion Cooling emulsion may contain toxic and polluting substances such as glycol.

They must not reach the environment. The disposal must be taken place by a

specialised waste management company.

2 .9 Signage

Following symbols and signs are found in the working area. They apply to the immediate

neighbourhood in which they are displayed.

WARNING:

Risk by illegibly signage!

Over the years stickers and signs may become dirty or defaced in any other way; so

that hazards are not recognized and necessary operating instructions have been

adhered This is a risk of severe injury!

Always keep safety, warning and operating instructions in a well legible

condition.

Immediately replace damaged or obliterated signs or labels.




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2 .9 .1 Mandatory s igns

Take notice of instruction

Only use the machine after reading the instructions!

2 .9 .2 Prohibi t ion s igns

Prohibitions for people with pacemakers

In the area of this sign a strong electromagnetically field is possible, which can disturb

or disable pacemakers.

Persons with pacemakers must not stand near the machine.

Prohibition for people with metal implants

Persons with metallic implants must not be allowed in the area of the machine.

Implants can heat themselves up or be drawn-in by the electro-magnetically field.

Operation with necklace is prohibited

Risk of entrapment or entanglement in moving parts.

Take off necklaces before entering the signed area.

Operation with tie prohibited

Risk of entrapment or entanglement in moving parts.

Take off tie before entering the signed area.

Operation with long hair prohibited

Risk of entrapment or entanglement in moving parts. Persons with long hair have to

wear a hair-net or hair cover.




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2 .9 .3 Warnings

Voltage

Ins so signed areas only skilled electricians are allowed to work.

Unauthorized people must not enter these signed working areas or open so signed

cupboards.

Automatic start

The start of the machine in production systems is indicated by a flashing light or

acoustic signal. From this moment on all works must be finished.

After signalling, leave danger zone.

Always maintain an adequate distance to all moving parts, risk of hands, hair and

clothing being drawn in.

Hot surface

Hot surfaces, such as hot machine parts, container and materials, may not always be

noticeable. Do not touch without protective gloves!




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2 .9 .4 Fire protect ion s igns

Fire alarm phone

The fire alarm phone may only be used in case of emergency.

Before fighting the fire, make an emergency call via fire alarm phone.

A fire alarm phone can be, in exception, even a simple phone that establishes a

connection via telephone directly to the fire department, the operating station or to a

person permanently present. In such cases, the following information is required:

WHO reports?

WHAT has happened?

HOW MANY are affected / injured?

WHERE has something happened?

WAIT for questions!

Fire extinguisher

Indication of a fire extinguisher.

Before fire extinguishers are brought to the fire, warn all persons in the danger zone or

help to escape from the area. Only remove the fire extinguisher to put out a fire.




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2 .9 .5 Exit s igns

First aid

The safety signs without an additional sign indicate a first-aid kit.

If further signs such as "medical station" or "first responders" are fitted, first aid

professionals are additionally available.

In case of an emergency (even for minor injuries) use the material in the first-aid kit for

first aid treatment of the injured person. When using or taking out first-aid materials

registrations must be made in the accident book.

Emergency exit

In a case of emergency, leave the danger zone through the emergency exit.

Emergency phone

In case of an emergency, use the phone to alert.

The following details shall be transmitted to the monitoring station:

• WHO is calling?

• WHAT happened?

• HOW MANY are affected / injured?

• WHERE has it happened?

• Wait for questions!

Escape

In a case of emergency, follow the suggested escape route in direction of the arrow.

Emergency evacuation routes must always be kept clear.




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3 Technical

specifications

3 .1 General

information

Specification High-Z S-400 High-Z S-720 High-Z S-1000

Length (L) 736 mm 1056 mm 1336 mm

Width (W) 570 mm 690 mm 870 mm

Height (H) 570 mm 570 mm 570 mm

Weight without

work surface and

tool

ca. 32,5 kg ca. 39,5 kg ca. 45 kg

Clamping surface

(LxW)

730 x 390 mm 1050 x 510 mm 1330 x 690 mm

Passage height 103 mm (from the upper edge of the frame)

Traversing ranges


X-axis 400 mm 720 mm 1000 mm

Y-axis 300 mm 420 mm 600 mm

Z-axis 110 mm 110 mm 110 mm

Figure 4: High-Z Machine generally

Z

X

Y




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Other parameters


Positioning speed

(Rapid traverse XY) 66 mm/sec1 66 mm/sec1 66 mm/sec1

working speed (XY) 50 mm/sec1 50 mm/sec1 50 mm/sec1

Positioning speed

(Rapid traverse Z) 30 mm/sec 30 mm/sec 30 mm/sec

Steps/U at 1/10-Step

Control

2000 2000 2000

Thread pitch XY 6 mm 6 mm 6 mm

Thread pitch Z 6 mm 6 mm 6 mm

Round bar guide

XY 22 mm 22 mm 22 mm

Circular waveguide

Z 16 mm 16 mm 16 mm

Programmable

resolution XYZ 0,003 mm 0,003 mm 0,003 mm

repeatability 0,01mm 0,01mm 0,01mm

backlash +- 0,03mm +- 0,03mm +- 0,03mm

Drive X-axis 2 Step motors Nanotec Type ST5918L3008-A

Drive Y axis 1 Step motor Nanotec Type ST5918L3008-A

Drive Z axis 1 Step motor Nanotec Type ST5918L3008-A

reference switch Meder Reed Sensors Type Mk04 non-contact on all three axes

1 Measured in the diagonal drive X + Y (depending on contour shape)




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3 .2 Power values

Feed drives X / Y / Z specification value unit

Power consumption per motor max. 4,2 A

3 .3 Operating condit ions

Environment Specifications value unit

temperature range 15-30 °C

Relative humidity maximum 60 %

Duration Specification value unit

Maximum operating time per session 100 h

Pause until the next session 2 h

3 .4 Working materials

Working materials Type

Low friction grease multipurpose grease

Acid and resin free

Low friction oil Fine mechanics oil

Acid and resin free

3 .5 Emiss ions

Specification Value Unit

Noise emissions ca. 50 dB(A)




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3 .6 Type plate

The type plate is located on the frame of the portal system (Figure 5 /Arrow) and includes the

following information:

Figure 5: Location of type plate

Figure 6: Type plate

Manufacturer

Type of plant

Year

Serial number

Version




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4 Structure and functions

4 .1 Overview

Figure Overview HIGH-Z

1 Stepper motor of the Z-axis

2 Terminal box of the stepping motor of the Z-

axis

3 Z-axis with carriage

4 Y-axis with carriage(Y-bridge)

5 X-axis with carriage

6 Stepper motors of the X-axis

7 Terminal boxes of the step motors of the X-

axis

8 Floating-bearing bumping-stop of axis

9 framework

10 Stepping motor control cable

11 Energy chain guide

12 Terminal box of the stepping motor of the

Y-axis

13 Stepper motor of the Y-axis

14 Reference switch XYZ

15 Round bar guide

1 2

3

4

5

6

7

9

10

11

12

13 14

15

8




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4 .2 Brief descript ion of the appl icat ion range

Usage of the machine

The machine is used in conjunction with a tool for:

Milling

Engraving

Cutting

Drilling

Laser Engraving

Grinding

Plasma cutting

Welding

Dosing

Measuring

Positioning

Short Description

The machine cannot function alone. The following additional components (accessories) are

necessary for operation:

Control which consists of a PC with the right configuration with struck up control software

(e.g. WinPc-NC, Mach3, USBCNC) and a stepper motor control (e.g. Zero3).

Tool with 43mm intake for direct clamping into the holder provided.

Accessories, see Appendix

The machine consists of an aluminium frame construction, which is kept open for large work

pieces.

Control via operating software

To control it requires a CNC-CAM-software.

In a design-/graphic-program (e.g. ConstruCAM 3D, Corel Draw, AutoCad, etc.) the drawings or

texts are created and stored in a suitable format. This data can be (e.g. WIN PC-NC) read by the

control software.

Via control the stepper motors for the axis-movement are controlled. By stepping motors and the

driven trapezoidal screw, a conversion of rotary motion into linear is carried out.




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4 .3 Module Descript ion

4 .3 .1 Z-axis with carriage

Figure 8a: Z-Carriage

1 Trapezoidal thread spindle

2 linear guides

The two linear guides (Figure 8a /2) guide into the inclusion of

the accessory bracket. The trapezoidal threaded spindle (Fig. 8a /

1) represents the Z-axis on which the accessory holder with a

suitable tool (4 inclusion) moves along the Z-linear

guides

Figure 8b: Z-Carriage

1 Reference switch Z-axis

2 Magnetic contact

The reference switch (Fig. 8b / 1) responds to the magnetic field

of the incoming homing magnet (Fig. 8b /2). If the magnet

is close enough the reed sensor of the switch turns on.

The reference switch operates as closing contact; in switched

state the signal circuit is closed.

HINT:

Reference switches are required for axes without absolute position encoder to

feature in the initialization of the axis by a known reference point (zero point of the

axis). From this position, all other positions are then calculated relative to the

process of the axis via software.

1 2

1

2




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4 .3 .2 Y-axis with carriage

Figure 9a: Y-Carriage

1 Linear guides (upper linear guide is covered)

2 Tool holder (43H7 holder)

3 Y-bridge

4 Trapezoidal threaded spindle (also behind the cover)

The two linear guides (Fig. 9a / 1) and the Trapezoidal Thread

Spindle located on the Y-bridge (Fig. 9a / 3) and represent the

Y-axis. Along the Y-Bridge is the tool holder (Fig. 9a / 2)which

can be moved with a suitable tool (43H7 holder)

Figure 9b: Y-Carriage

1 Reference switch Z-axis

2 Magnetic contact

The reference switch (Fig. 9b / 1) responds to the magnetic field

of the incoming homing magnet (Fig. 9b / 2). If the magnet

is close enough the reed sensor of the switch turns on.



HINT:





1

2

3

1

2




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4 .3 .3 X-axis with carriage

Figure 10a: X-Carriage

1 Y-bridge

2 linear guide

3 Trapezoidal thread

spindle

The figure shows the X-linear guide (Fig. 10a / 2) with

trapezoidal threaded spindle (Fig. 10a / 3) from one side of the

machine.

The second X-linear guide with trapezoid thread spindle is

positioned symmetrically on the other side of the machine.

The two linear guides represent the X-axis, on which the Y-

bridge is moved (Fig. 10a / 1) along the X linear guides.

Figure 10b: X-Carriage

1 Reference switch Y-axis

2 Magnetic contact

The reference switch (Fig. 10b / 1) responds to the magnetic

field of the incoming homing magnet (Fig. 10b / 2). If the

magnet is close enough the reed sensor of the switch turns on.



HINT:





3

2 1

1 2




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Figure 10c: X-Carriage

1 stop (M8 screw)

2 magnet holder of the X axis

3 mounting screw magnet holder (M6 screw)

The M8 screw (Fig. 10c / 1) serves as a stop for the magnet

holder (Fig. 10c / 2). This stop is required to locate the factory

setting, if for reasons of user-defined settings the magnet holder

was transferred.

To move the magnet holder (Fig. 10c / 2) loosen the fixing screw

(Fig. 10c / 3), move the magnet holder along the groove to the

desired position and secure with the fixing screw to prevent

loosening

HINT:

If the position of the magnet holder of the X-axis is changed, settings must be taken

into account in the control software under the topic “working space”.

4 .3 .4 Tool holder

Figure 11: Tool holder 43H7

On the tool holder of the Z-axis (Fig. 11/1) are some of the most

important additional available tools attached (see Appendix

"Accessories").

4 .4 Controls

The machine does not have its own controls for moving the axes. This is possible with separate

interfaces (e.g. stepper motor control Zero3)

1

1

2 3




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4 .5 Connections

The connectors of the step motor cables or control line ST are

labelled as follows:

Connector X1 stepping motor of the X-axis.

Connector X2 stepping motor of the X-axis.

Plug Y stepping motor of the Y-axis.

Plug-Z stepper motor Z-axis.

Connector ST Emergency, Ref-switch and socket Pin15.

Fig. 13: Connection ST and. Motor

connection

The connection of the stepper motors or the reference

switch and emergency stop signal are carried out via

depicted lines marked on each Sub-D connector (Fig. 13).

For pin assignment see Figure 14 and Figure 15.

Ground Connection to Zero-3 Controller

Fig. 12: Stepper motors

Fig. 13a: Ground

Fig. 13b: Zero-3




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4 .5 .1 Control s ignals (ST)

Figure 14: Belegung

Steuerstecker

Sub-D

Pin Nr. Signal

1 Limit C / Pin15 jack High-Z

2 limit X

3 limit Y

4 limit switch Z

5 Emergency stop (closed = OK, open = stop)

6 N.C.

7 N.C

8 N.C.

9 Ground, shield

4 .5 .2 Motor connector (X1,X2,Y,Z)

Figure 15: Belegung Motorstecker

Sub-D

Pin Nr. Signal

1+6 Motor winding A +

2+7 Motor winding A-

3+8 Motor winding B +

4+9 Motor winding B-

5 Ground, shield




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4 .5 .3 MiniXLR pin socket (Pin15)

Figure 16: miniXLR socket

The pin 15 is connected via socket which is available on the

machine (Fig. 16). This allows additional optional applications

(e.g. zero button, length sensor, 3D buttons) that can be

integrated via Pin15.

(Info for pin assignment see Figure 17)

Figure. 17: Anschluss Pin15

Pin Nr. Signal

1 Signal contact 1

2 N.C.

3 Signal contact 2




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4 .6 Work and danger areas

4 .6 .1 Working area

Figure. 18: Working area

• PC (Accessories)

• area of the tool holder (Fig. 18/1) (when turned off)

• Range of motion of the axes (Fig. 18/2) (when turned

off)in order to clamp work pieces

4 .6 .2 Danger zone

Figure. 19: Danger zone

Total area of machinery in operation

1

2




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5 Transport, packaging and storage

HINT:

As part of the installation and the further use the operator or maintenance personnel

must be entrusted by the operator with the handling of packages. Always observe the

instructions listed below.

5 .1 Safety instruct ions for transport

Suspended loads

WARNING:

Danger to life due to suspended loads!

When lifting operations are carried out loads can swing out and fall off. This may

lead to serious injury or death.

Never stand under or into the swivel area of a suspended load.

Loads are only to be moved only under supervision.

Use only approved lifting gear and lifting gear with sufficient load-bearing

capacity.

Do not use damaged or frayed lifting equipment such as ropes and straps.

Lifting equipment such as ropes and straps must not be laid on sharp edges

and corners do not twist or knot.

When leaving the workplace settle the load.

Eccentric focus

WARNING:

Risk of injury by falling or tipping packages!

Packages may have an off-centre focus. The wrong kind sling gear attachment can

tilt the packing crate and cause life-threatening injuries.

Observe the markings and details on the focus on the package.

Attach the crane hook so that it is directly above the centre of gravity.

Lift cautiously and observe whether the load tilts.




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Improper transport

HINT:

Property damage due to improper transport!

Improper transportation can cause considerable material damage.

When unloading delivered packages and when transporting on the

premises, proceed with caution and adhere to the symbols and instructions

on the packaging.

When slinging the load all attachment points provided by the manufacturer

have to be used in accordance with the specifications.

Do not remove packing until just before the installation.

5 .2 Transport inspect ions

Check the delivery immediately on receipt for completeness and transport damage.

Proceed in case of visible damage as follows:

Do not accept the delivery or only under reserve.

Record the scope of the damage on the transport documents of the carrier, or on the delivery

note.

Lodge complaint.

HINT:

Lodge a complaint for each defect, as soon as it is recognised. The claims for damage

must be filed in the lawful reclaim periods.




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5 .3 Packaging

Regarding packaging

The individual packages are packed according to the expected transport conditions.

Environmentally friendly material is used exclusively for the packaging.

The packing has the function of protecting the individual components against damage, corrosion,

etc., until they are finally assembled. Therefore, do not damage the packaging and only remove

immediately before installation.

What to do with packing materials

Dispose of packaging material in accordance with the respective valid laws and local regulations.

Non-central centre of gravity

HINT:

Danger for environment due to improper disposal!

Packing materials are valuable raw materials and can continue to be used in many

cases or sensibly reconditioned and recycled. Incorrect disposal of packaging

materials, may lead to risks to the environment.

Dispose packaging material environmentally friendly.

Adhere to the valid local regulations for disposal.




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5 .4 Symbols on packaging

The following symbols are shown on the packaging. Always heed the symbols during transport.

Fragile

Identifies packages with fragile or delicate contents.

Treat the package with care, do not drop or bump it.

Do not stack

In the designated packages or goods should not be stacked.

Protect from moisture

Protect packages from moisture and keep dry.

5 .5 Transport

Sling points

The machine may only be transported and slinged in the frame.

Transport of pallets with the crane

Transport pieces, which are fastened on a pallet can be transported by a crane under the following

conditions:

Crane and lifting gear must be designed for the weight of the transported items.

The operator must be authorised to operate the crane.




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Slinging

protective equipment: Industrial safety helmet

Figure 20: lifting gear

1 Sling on ropes, belts accordingly (Fig. 20) to the pallet and

secure pallet against slipping.

2 Check whether the transport pieces are not damaged by the

slinging materials. If necessary, use other slings.

3 Make sure that the pallet with off-centre gravity cannot tip.

4 Start the transport.

Transport of pallets with a forklift

Transport pieces, which are attached to pallets can be transported under the following conditions

using a forklift:

The fork lift must be rated for the weight of the transport pieces.

The transport package shall be securely fastened on the pallet.

The folk lift driver must be authorized to drive industrial trucks with driver's seat or driver's

cab according to national regulations.

Transport

Figure 21: Transportation by forklift

1 Drive the forklift with the forks between or the holms of

the pallet.

2 Drive the forks so far that they protrude on the opposite

side.

3 Make sure that the pallet with off-centre gravity cannot tilt.

4 Lift the pallet with transport piece and start the transport.




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5 .6 Storage

Storage of packages

Packages should be stored under the following conditions:

Do not store outdoors.

Dry and dust free.

Not exposed to corrosive media.

Protect from sunlight.

Avoid mechanical shocks.

Storage temperature: 10 to 35 ° C.

Relative humidity: max. 60%.

For storage longer than 3 months regularly check the general condition of all parts and packaging.

If necessary, refresh or renew the preservative.

HINT:

Further instructions for storage may be found on the packaging, which go beyond

the requirements listed here. These comply accordingly.




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6 Instal lation and commissioning

6 .1 Safety instruct ions for the instal lat ion and commiss ioning

Suspended loads

WARNING:

Danger to life due to suspended loads!

When lifting, loads can swing out and fall off. This may lead to serious injury or

death.

Never stand under or into the swivel area of a suspended load.

Loads are only to be moved only under supervision.

Use only approved lifting gear and lifting gear with sufficient load-bearing

capacity.

Do not use damaged or frayed lifting equipment such as ropes and straps.

Lifting equipment such as ropes and straps must not be laid on sharp edges

and corners do not twist or knot.

When leaving the workplace settle the load.

Improper installation and commissioning

WARNING:

Risk of injury by improper installation and commissioning!

Improper installation and commissioning can lead to severe injuries and substantial

property damage.

Before starting any work sufficient installation freedom is required.

Handle open, sharp-edged components with care.

Maintain order and cleanliness at the installation site! Loosely stacked or

scattered components and tools are accident sources.

Install components professionally. Comply with the specified screw

tightening torques.

Secure components so they do not fall down or fall over.

Note following guidelines before commissioning:

Ensure that all installation work in accordance with the information and

instructions were carried out and completed in this guide. Ensure that there are

no persons in the danger zone.




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Screw tightening torques

HINT:

Property damage caused by incorrect screw tightening torques!

All screws on the machine have been tightened before delivery to the appropriate

torque.

Additional tightening leads to undesired tensions in the machine and thus to

inaccurate machining of the work pieces.

Tighten No screws on the machine!

6 .2 Preparations

6 .2 .1 Instal l machine

Personnel: Specialist personnel

Safety equipment: Protective clothing

Safety shoes

Industrial protective helmet

ATTENTION:

Risk of injury by under-sized buildings!

Overload of ceiling structures can lead to serious damage and personal injury!

If the machine is situated on a cantilevered building ceiling, note the

dynamic loads due to the movements.

Uneven ground

HINT:

Material damage caused by uneven ground!

Due to uneven ground deformations are caused within the machine. This results in

an imprecise machining of the work pieces.

Place the machine on a flat and level surface.

1. Place the machine on a level, vibration-resistant surface.

2. horizontal align (Utilities water balance).




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6 .2 .2 Instal l worktop

The worktop (not included) may be as following, according to mounting maximum dimensions.

Figure 22: Clamping range

Modell HIGH-Z Dimensions of the worktop in frame

S-400 610 x 390mm

S-720 930 x 510mm

S-1000 1210 x 690mm

Modell HIGH-Z Dimensions of the worktop on frame

S-400 730 x 390mm

S-720 1050 x 510mm

S-1000 1330 x 690mm

Fixing the worktop is done by yourself. As a recommendation, grooves in the frame of the

aluminium profile in conjunction with matching T-nuts (8mm groove width) can be supplied.

6 .3 Instal lat ion

6 .3 .1 Connecting the computer

HINT:

The connection of the PC / computer to the stepper motor is controlled according to

the information belonging to the stepper motor controller manual.




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6 .3 .2 Connecting the s tepper motor and control cable

ATTENTION:

Risk of tripping and falling!

Exposed wires on the ground can lead to tripping or slipping.

On the ground laid cables should be covered.

Do not lead past corners and sharp edges.

Avoid chafing.

Visibly mark line course.

Figure 23: Connections

The connectors of the stepping motor, and control lines (Fig. 23

/ arrow) are labelled.

Personnel: specialist personnel

Figure 24: Stepper motors of axes

1 Connect the plug of the stepper motor and control cable

with the following assignment to the stepper motor

controller:

X-axis stepper motor (Fig. 24/1) to terminals X1 and

X2 of the stepper motor controller

Y-axis stepper motor (Fig. 24/2) to terminal Y, the

stepping motor control

Stepper motor Z-axis (Fig. 24/3) to terminal Z of the

stepper motor control

• Emergency stop switch, limit and reference switches

to port ST stepper motor control

2 Secure cable connections with the knurled screw from

loosening.

1

2

3




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6 .3 .3 Instal l ing Accessories

HINT:

The equipment installation is carried out according to the specifications of the

accessories associated operating and assembly instructions.

WARNING:

Risk of injury due to improperly mounted accessories!

Improperly mounted accessories can lead to uncontrolled falling or throwing out

during operation and cause serious injury to skin and eyes.

Mount accessories professionally according to the safety regulations.

Install milling motor Personnel: Specialist personnel

Figure 25: Tool holder with milling

1 Tool, for example milling motor with 43mm neck Euro

(Fig. 25/1) insert in the tool holder (Fig. 25/2) on the Z

carriage.

2 Tighten screw (Fig. 25/3) lightly until a clamping is done

3 Check milling motor for tightness in the accessory holder.

HINT:

Property damage caused by excessive tightening!

When excessive tightening the screw for mounting the milling motor, the main

bearing of the cutter motor may be damaged.

Never tighten the screw (Fig. 25/2) for fixing the milling motor, excessively.

Only use the short side of an allen key for manual tightening!

2

1

3




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6 .4 Ini t ia l s tart -up

Personnel: Specialist personnel

1 Make sure that the machine is installed and aligned.

2 Ensure that the stepper motor, and control lines are connected to the stepper motor controller

3 Make sure that the computer is connected to the stepper motor control of the machine.

4 Ensure that required accessory is installed and connected to the power supply.

5 Ensure that the appropriate software is installed on the PC.

6 Ensure the tightness of all connections.

HINT:

The individual materials have different coefficients of expansion. At an ambient

temperature of 20-25 ° C it is ensured that no significant impacts occur during

processing. Therefore, it is recommended to maintain an ambient temperature of 20-

25 ° C when operating the machine.




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7 Operation

7 .1 Safety guidel ines for operation

Improper operation

WARNING:

Risk of injury by improper operation!

Improper operation can result in serious injuries and significant property damage.

Perform all operations in accordance with the information and instructions of

this manual. Note the following before beginning work:

Make sure that all covers and safety devices are installed and

working properly.

Ensure that there are no persons in the danger zone.

Never bridge or disable safety devices during operation.

7 .2 Operations before usage

1 Make sure that all covers are installed on the machine.

2 Ensure the tightness of all connections.

3 Make sure that none of the emergency stop switch is pressed.

4 Check the ambient temperature.

HINT:

The individual materials have different coefficients of expansion. At an ambient

temperature of 20-25 ° C it is ensured that no significant impacts occur during

processing. Therefore, it is recommended to maintain an ambient temperature of 20-

25 ° C when operating the machine.

7 .3 Switching on

Personnel: Operator

1 Turn on the computer and boot the software.

2 Clamp work piece




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3 Ensure that required tool is in the tool holder, if necessary, change the tool, and see the separate

operating instructions for the accessories.

4 Ensure that no tools or other foreign objects are in the machine or system.

5 Make sure that no persons are in the danger zone.

6 Connect required accessories to the provided power supply.

7 Switch on the stepper motor control; refer to the separate operating instructions for the step

motor control.

8 Perform reference run.

9

10

Zero point determination.

Start Job.

7 .4 Activi t i es during operation

7 .4 .1 Operating machine

Personnel: Operator

Safety equipment: protective clothing

Safety shoes

Goggles

protective gloves

Hearing protection

Protective cover

Rotary tools

WARNING:

Risk of injury from rotating tools!

In spindles clamped tools may result in serious personal injury or property

damage.

Before starting work, ensure that all covers and safety devices are

installed and working properly.

• Do not reach into moving tool during operation.

• Before replacing the tools always pull power plug of the milling motor

or turn off the machine and secure against reconnection.




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Axis movements

WARNING:

Risk of injury due to axis movements!

Collision of people with components of the machine (Y-bridge, mobile unit, rotary

table with the work piece, tool) can lead to serious injuries.

Keep anybody parts away from in-between the moving parts and end stops

of the axes.

Do not grab in gaps between adjacent components of linear guides and

access adjacent components

Perform work on the linear guides only at standstill.

In the work area wear personal protective equipment.

Magnetically fields

DANGER:

Danger to life due to magnetic fields!

Magnetic fields of stepper motors can cause serious injury and even death and

substantial property damage.

Persons with pacemakers must not go near the machine itself. The function

of the pacemaker may be affected.

People with metal implants should not be in the vicinity of the machine

itself. Implants can heat up or be attracted

Before servicing take off metal objects (jewellery, watches, writing

instruments, etc.).

Do not bring any electronic devices in the vicinity of the magnetic source.

These could be damaged.

No storage media, credit cards, etc. placed in the vicinity of the magnetic

source. Data can be deleted.

Falling materials

WARNING:

Injuries caused by falling materials!

In operation, chips, tools (or parts thereof) may fall uncontrollably down or may be

thrown out and cause serious injury to skin and eyes.

Wear face shield or fully enclosed goggles, protective clothing, gloves and

safety shoes.

If particles enter the eye, seek immediate medical attention.




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Unexpected start of the machine

WARNING:

Risk of injury from unexpected starting of the machine!

The machine and the tools may start unexpectedly, change direction or stop. Limbs

can get captured.

Make sure that no body parts enter the danger area of the machine.

Secure work area from accidental access.

Highly inflammable substances

WARNING:

Fire hazard due to flammable materials!

Organic dusts from coal or wood or inorganic dust of magnesium, aluminium,

zinc or titanium can catch fire and cause serious or even fatal injuries.

Within the danger zone and in the vicinity do not smoke. Do not use

open flames or sources of ignition.

Keep fire extinguisher ready.

• Processing of light metal alloys such as magnesium, aluminium, zinc

and titanium without suction and appropriate security measures is not

allowed.

Stop work immediately in case of fire. Evacuate danger area until the all-

clear is given.

Cooling emulsion

ATTENTION:

Risk of health damage by contact with cooling emulsion!

Contact with cooling emulsion can lead to health damage.

Avoid skin contact.

Remove the cooling emulsion immediately from the skin.

Do not inhale vapours

Operation with coolant

HINT:

For more information, refer to the manufacturer's instructions of the coolant.




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7 .4 .2 Change tool

Personnel: Operator


Safety shoes

protective gloves

1 Make sure that the tool (e.g. milling motor, tangential knife, etc.) is de-energized

(Connecting cable, pull out the mains plug or power button press)

ATTENTION:

Risk of burns from hot surfaces! Risk of being cut by tools and chips!

Contact with hot components can cause burns. Tools and chippings can cause injury

when touched.

- When changing tools, wear protective gloves.

2 Change tool, see the separate operating and assembly instructions

3 Make sure that the tool is again provided with voltage (connection cable, connect the power

plug or switch power button)

7 .5 Switching off

1 Turn power switch on the stepper motor control to "0" or "Off"; see separate operating

instructions for the step motor control.

2 Stop software for the machine on the computer.

3 Shut down computer.




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7 .6 Activi t i es af ter use

Personnel: Operator


Safety shoes

protective gloves

1. Turning off the machine.

ATTENTION:

Risk of injury by chips!

Chips can be sharp and cause deep lacerations.

Always wear protective gloves when removing chips.

2. Clean the machine (see chapter 8.4).

7 .7 Emergency Shutdown

In hazardous situations, movements of components must be stopped as soon as possible and the

power supply must be switched off.

Stopping in an emergency

1 Immediately activate emergency stop by emergency stop device.

2 If there is no danger for your health, remove persons from the danger zone.

3 If necessary, initiate first aid measures.

4 Call Fire department and / or ambulance service.

5 Inform the responsible person on site.

6 Turn the machine off and secure it against being switched on again.

7 Keep access routes for emergency vehicles free.

8 Instruct rescue vehicles.




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8 Maintenance

8 .1 Safety Instruct ions for maintenance

Moving components

WARNING:

Risk of health damage by contact with cooling emulsion!

Contact with cooling emulsion can lead to health damage.

Avoid skin contact.

Remove the cooling emulsion immediately from the skin.


Electrical System

DANGER:

Danger to life due to electric current!

Contact with live components can be fatal. Activated electrical components can run

uncontrolled movements and cause serious injury.

Switch off the electrical supply before starting work and secure against

reconnection.

Improperly performed maintenance

WARNING:

Risk of injury by improperly performed maintenance!

Improper maintenance can lead to severe injuries and substantial property damage.

Before starting any work, ensure installation freedom.



If components have been removed, ensure correct assembly, reinstall all

fasteners and note correct screw tightening torques.

Note following before re-starting :

Ensure that all maintenance work has been done in accordance with the

information and instructions were carried out and completed in this guide.


Make sure that all covers and safety devices are installed and working

properly.




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Environmental protection

Observe the following instructions to protect the environment during maintenance:

On all lubrication points which are supplied with lubricant by hand, remove escaping,

used or excess grease and dispose in accordance with applicable local regulations.

Decant oils in suitable containers and dispose according to local regulations.

Catch oil / fat-containing cloths in suitable containers and dispose according to local

regulations.

8 .2 Spare parts

WARNING:

Risk of injury due to using unapproved replacement parts!

The use of incorrect or faulty spare parts can lead to hazards to personnel and

malfunction or failure of the machine.

Only use original spare parts from the manufacturer or manufacturer-

approved replacement parts.

If in doubt always contact the manufacturer.

Loss of warranty

The use of non-approved spare parts invalidates the manufacturer's warranty.

Obtain spare parts from authorized dealers or directly from the manufacturer.

The spare parts list is available on request.

Specify following points when ordering spare parts:

Type

Year built

Serial no.

Version

Amount

Identification

desired delivery method (mail, cargo, sea, air, express)

shipping address

Spare part orders without above information will not be considered. If no specification is made

regarding the shipping method, shipping will be at the discretion of the supplier.




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8 .3 Maintenance Schedule

In the following sections, the maintenance is described that is necessary for optimum and trouble-

free operation of the machine. If increased wear can be seen during regular inspections reduce the

required maintenance intervals according to the actual wear and tear. For questions about

maintenance work and intervals, contact the manufacturer.

Refer to the separate operating instructions, for the maintenance of the supplied components.

Modell HIGH-Z Series S-400 / S-720 / S-1000

Interval Maintenance To be carried out by

Daily Cleaning the machine Operator

Check the machine for damage and wear qualified personnel

10 Hours Grease Trapezoidal Thread Spindle qualified personnel

Oil linear guides qualified personnel

50 Hours Grease motor bearings through the provided

funnel type lubrication fitting

qualified personnel

As required Clean the machine from the outside with a cloth

DIN 61650

Operator




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8 .4 Maintenance

8 .4 .1 Cleansing of the machine

Regular maintenance of the machine prevents sticking of moving parts.

Personnel: Operator


Safety shoes

protective gloves

1 Turn power switch on the stepper motor control to "0" or "Off"; see separate operating

instructions for the step motor control.

2 Free machine from chips.

ATTENTION:

Risk of injury by chips!

Chips can be sharp and cause deep lacerations.

Always wear protective gloves when removing chips.

3 Free Trapezoidal Thread Spindle and linear guides from chips

4 Clean the entire machine with a slightly oily cloth DIN 61650




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8 .4 .2 Lubricate machine

The lubricants reduce wear, protect against pollution, reduce corrosion and prolong the service life

by their properties.

For supplies, see chapter 3.4.

Grease Trapezoidal Thread Spindle

Personnel: Qualified personnel


Safety shoes

Chemical-resistant gloves

Figure 26: Lid Y-axis

1

2

3

Switch off the machine and secure against re-start.

Loosen and remove the four screws (Fig. 26/2).

Remove the cover (Fig. 26/1) on the Y-axis.

ATTENTION:

Risk of health damage by contact with oil and grease!

Contact with oil and fat can lead to health damage.

Avoid skin contact.

Remove Oil and grease immediately from the skin.


1

2

2

2




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Oil linear guides



Safety shoes


Figure 28: linear guides of the X-and

Z-axis

1

2

Switch off the machine and secure against re-start.

Grease the linear guides of the X-axis (Fig. 28/1), the Z-

axis (Fig. 28/2) well using a low-friction grease wetted

cloth DIN 61650 or alternatively apply the fat with a

suitable brush.

Figure 29: Cover Y-axis

2 Loosen and remove the four screws (Fig. 29/2).

3 Remove the cover (Fig. 29/1) on the Y-axis.

Figure 30: Linear guide the Y-axis

4 Grease the linear guides of the X-axis (Fig. 30/1) well using

low-friction grease soaked cloth DIN 61650 or alternatively

apply the grease with a suitable brush.

1

2

2

2

1

1

2




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Grease Lubrication nipple on the motor bearings



Safety shoes


Special tool: Grease gun

Grease nipple X-axis (2 pcs.)

Figure 31: grease nipple X-axis

1 Switch off the machine and secure against re-start.

2 Put Grease Gun onto the grease nipple on the X-axis.

3 Operate Grease Gun once or twice.

4 Remove grease gun.

5 Put Grease Gun onto the grease nipple of the other X-axis

6 Perform working steps 2-4.




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Grease nipples of the Y-axis (1 pc)

Figure 27: Trapezoidal threaded

spindle

1.

2.

Switch off the machine and secure against re-start

Grease the Trapezoidal Thread Spindle of the X-axis

(Fig. 27/1), the Y-axis (Fig. 27/2) and the Z-axis (Fig.

27/3) well using a low-friction grease wetted cloth DIN

61650 or alternatively apply the fat with a suitable brush.

Figure 32: grease nipple Y-axis

7 Put Grease Gun onto the grease nipple on the Y-

axis.

8 Press Grease Gun once or twice.

9 Remove grease gun.

Grease nipples of the Z-axis

(1 pc)

Figure 33: grease nipple Z-axis

10 Place Grease Gun onto the grease nipple on the Z-

axis.

11 Press Grease Gun once or twice.

12 Remove Grease Gun.

1 2

2

3

2




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8 .5 Measures af ter maintenance

After completion of maintenance and before turning on the machine, perform the following steps:

1 Check all previously loosened screw connections for tightness.

2 Verify that all previously removed protective devices and covers are reinstalled correctly.

3 Ensure that all tools, materials and other equipment used were removed from the work area.

4 Clean work area and remove any spilled substances such as fluids, processing material or

similar materials.

5 Ensure that all safety devices on the machine function properly.




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9 Failures

In the following chapter possible causes of interference are described and how to solve them.

With increasingly occurring disorder shorten the maintenance intervals according to the actual load.

For malfunctions that cannot be remedied by the following instructions, contact the manufacturer.

9 .1 Cautions for Troubleshooting

Electrical System

DANGER:

Danger to life due to electric current!

Contact with live components can be fatal. Activated electrical components can

run uncontrolled movements and cause serious injury.

Before starting work, switch off electrical supply and secure against

reconnection.

Moving components

WARNING:

Danger of injury by moving parts!

Rotating and / or linearly moving parts can cause severe injury.

Before starting maintenance on movable components, turn off machine

and secure against reconnection. Wait until all parts have come to a

standstill.

In hazardous area wear tight-fitting protective clothing with low tensile

strength




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Improperly executed fault elimination

WARNING:

Risk of injuries caused by improper fault elimination!

Improperly performed work and troubleshooting can cause serious injury and

considerable damage to property.

Before starting any work sufficient installation freedom has to be given



• If components have been removed, ensure correct assembly, reinstall

all fasteners and tighten with screw tightening torques.

Note the following before restarting:

Ensure that all work and troubleshooting according to the information

and instructions in this manual have been carried out and completed.


Ensure that all covers and safety devices are installed and working

properly.

Response to malfunctions

1 For malfunctions that constitute an immediate danger to persons or property, immediately

initiate emergency stop

2 Determine cause of malfunction.

3 If the troubleshooting requires work in the danger area, turn off the machine and secure against

reconnection. Inform responsible about disorder immediately

4 Depending on the type of disorder this can be eliminated by authorized personnel.

The fault table listed below provides information about who is entitled to eliminate

the fault.




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9 .2 Diagnosis Chart

description of the

error

Cause Remedy Personnel

Machine has no

function

Emergency stop button

has been pressed

Cancel the emergency

stop

Operator

Toggle Signal is missing See pin assignment in

software

qualified

personnel

Control cable broken repair Manufacturer

Stepper motor stands Stepper motor (X, Y and

/ or Z-axis) is overloaded

Check connecting line if

required, check control,

see separate instructions

of the controller.

qualified

personnel

step loss Stepper motor of the X-

axis (X1 and / or X2) is

overloaded

Check machine

perpendicularity

qualified

personnel

Travel speed too high Correct the setting in

software

Operator

-the bridge is not at

right angles to the X

axis

Step losses, power

failure, physical

influence

(see chapter 9.3.2) Operator


software

Operator

Angular deviation in

the milling result

Y-the bridge is not at

right angles to the X axis

(see chapter 9.3.2) Operator


software

Operator

Cracking or loud noise

when driving the axes

PCI-interface/Parallel

port is defective

Stop the operation and

contact manufacturers

manufacturer

Lack of maintenance Lubricate spindle waves Operator

Hard lock error

occurred

USB dongle was not

found (WIN PC-NC

Economy)

Check the USB dongle

for proper connection

Operator




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description of the

error

Cause Remedy Personnel

Real-time module is

blocked

On Windows, other

programs are still

running in the

background

Close programs in the

background of Windows

Operator

Energy saving mode for

the USB port is active

Disable power saving

mode in the BIOS

qualified

personnel

Machine travels a

short distance and

stops abruptly

USB dongle is not

inserted properly or not

at all

Check the USB dongle

for correct fit

Operator

Machine jammed and

cannot be moved

Lack of care and

maintenance

Clean, re-lubricate if

necessary repair by

manufacturer

Operator /

manufacturer

Machine does not

recognize the reference

switch

Feed homing in software

incorrectly set

Set guideline 5mm/sec in

software

qualified

personnel

Reference switch is

defective

Replacement or repair Personnel /

Manufacturer

Increased backlash Worn Nylatronnut

achieved by lack of

maintenance or reached

service life

Replacement or repair manufacturer

Trapezoidal spindle

worn by lack of

maintenance

Replacement or repair manufacturer

If a disorder in the fault table is not included, please contact Customer Service.

See the separate operating instructions regarding the correcting of fault of the

supplied components.




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9 .3 Problem resolut ion

9 .3 .1 Cancel the emergency s top

Personnel: Operator

Figure 34: Emergency stop button

1 Determine and remedy the fault cause.

2 Unlock the emergency stop button by turning (Fig. 34)

twice.

9 .3 .2 Check axes for perpendiculari ty


Safety

equipment:

protective clothing

Safety shoes

1 Check the Y-axis to the X axis on squareness, where necessary, re-align using the

operation description for aligning the machine regarding perpendicularity (see chapter

9.3.3)

2 Start reference run with zero-point approach; see separate instructions of the software.




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9 .3 .3 Descript ion of process for a l igning the machine with

respect to perpendiculari ty

Requirements: A complete structure of the portal system, including controller, PC and

software.

Using the control software of the machine (X-axis) drive against the movable bearing brackets of

the X-axis (see chapter 4.1) by manual, slow speed and stop for a short time(max. 5 mm / s).

Thereby the two stepper motor drives of the X-axis are synchronized, and the Y-bridge with the X-

axis is aligned at right angles. After this procedure, retract the Y-Bridge by about 30mm from the

stop blocks (depending on the position of the magnet holder of the X-axis) and then initiate a

reference run. The machine is ready for operation.

HINT:

Property damage caused by non-observance of perpendicularity!

Ignoring the perpendicularity can cause considerable damage to the mechanics.

HINT:

If in doubt please contact the customer service "customer service" on page 7.

9 .4 Commiss ioning af ter faul t has been rect i f ied

Perform the following steps to restart after correcting the fault:

1 Reset the emergency stop devices.

2 Acknowledge the fault of the control.

3 Make sure, that nobody is sure no persons in the danger zone.

4 Start according to the instructions in chapter "Operation".




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10 Dismantling and disposal

Once the maximum lifetime of the machine is reached, the machine must be dismantled and

environmentally friendly disposed.

Disassembly should only be performed by qualified personnel.

Work on the electrical system may only be performed by qualified electricians.

10.1 Safety regulat ions for the disassembling and disposal

Improper disassembling

WARNING:

Risk of injury from incorrect disassembly!

Residual stored energies, angular components, peaks and corners on or in the

machine or on the required tools can cause injury.

Before starting any work ensure sufficient space.

Take care with sharp-edged components.

Maintain order and cleanliness in the workplace! Loosely stacked or


Disassemble components professionally. Note partially high weight of

the components. If necessary, use lifting equipment.

Secure components so they do not fall down or fall over.

•If in doubt consult the manufacturer

10.2 Disassembling

Before beginning with dismantling:

Switch off the machine and secure against restart.

Discharge all power supply from the machine, physically separate stored residual energy.

Remove the operating and auxiliary materials and residual processing materials and dispose

environmentally friendly.

Then clean modules and components in a professional manner and in accordance with applicable

local safety and environmental regulations.




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10.3 Disposal

If no return or disposal agreement has been made, select dissected components for recycling:

• Scrap metals.

• Plastic items for recycling.

• Other components dispose sorted by material nature.

HINT:

Threat to the environment due to improper disposal!

Incorrect disposal may cause environmental hazards may.

• electrical scrap, electronic components, disposal of lubricants and other excipients

must be carried out by authorized companies.

• If in doubt obtain information on environmentally responsible disposal at the local

municipal authority or specialized disposal companies.




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11 Appendix

11.1 Accessories

For the machine, there is a wide variety of applications.

Here is an excerpt from our catalogue of comprehensive range of accessories:

Machine extensions

- Enclosures, sub-racks, power arms,

- T-slot plates, T-slot plates on head frame

Work holding

- Vacuum tables and pumps, clamps, nuts

Tools milling, engraving, drilling

- Spindles, tool change spindles, collets, etc.

- Cutter for many different applications and materials, engraving, drill

- Axes of rotation and jaw chuck, depth sensor, tool length sensor, suction, minimum

quantity lubrication etc.

Tools for various applications

- Tangential cutting (oscillating or fixed)

- grooving module

- Laser engraving unit

- Laser scanning unit

- Plasma torch

- GranitoGrav (module for stone engraving)

Hardware and Software

- PC's and Monitors

- Radio remote control

- CAD / CAM software, font packs, specialized software

If interested, please contact our Customer Service by email or phone.

We will be pleased to advise you and give you an exact offer for your requirements!

Numerous suggestions and information is also available on our website.




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12 Customer Service

For technical information, please contact our Technical Customer Service:

Address:

CNC-STEP e.K.

Siemensstraße 13-15

D-47608 Geldern

Phone: +49 (0)2831/91021-50 (Mo. - Fr. 07.00 - 15.00 Uhr)

Mobile: +49 152 22345755

Only in urgent cases

(Mo. - Do. 15.30 - 18.00 Uhr)

Fax: +49 (0)2831/91021-99

E-Mail: [email protected]

Web: www.cnc-router.com

If you have questions, please contact our customer service via e-mail or phone.

We advise you gladly.

Numerous suggestions and information can be found on our website:

www.cnc-router.com



operating instructions high-z standard-series - cnc-step · 3/14/2015 · cnc-step e.k....

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